TM 10-3930-255-20 ORGANIZATIONAL MAINTENANCE MANUAL …

TM 10-3930-255-20

DEPARTMENT OF THE ARMY TECHNICAL MANUAL

ORGANIZATIONAL MAINTENANCE MANUAL

ORGANIZATIONAL MAINTENANCE MANUALTRUCK, LIFT, FORK, ELECTRIC

SOLID RUBBER TIRES, 2000 LB. CAPACITYARMY MODEL MHE-197, BAKER MODEL FTD-020-EE

FSN 3930-724-4058 (100-IN LIFT)FSN 3930-965-0075 (130-IN LIFT)

This copy is a reprint which includes currentpages from Change 1.

HEADQUARTERS, DEPARTMENT OF THE ARMYAPRIL 1965

SAFETY PRECAUTIONS

Operation

Refer to TM 10-3939-255-10 for safety precautions to be observed during operation of the forklift truck.

Hydraulic System

Before working on any part of the hydraulic system, be sure-

1. Lift carriage is fully lowered.

2. Mast is tilted fully DOWN.

3. All hydraulic pressure is relieved from unit or hose to be serviced.

4. All personnel and materiel are clear, should some system be operated accidentally.

5. Disconnect battery at charging receptacle, except when battery power is required to support the maintenancebeing done.

Electrical System

1. Avoid contact with spilled electrolyte. It is corrosive to most metals and fabrics and can burn skin if notwashed off immediately with running water.

2. Be very careful of flame, smoking, or creating sparks by short circuiting near charging or recently chargedbatteries. Hydrogen gas given off during charging is explosive and easily ignited.

3. Disconnect battery at charging receptacle, except when battery is needed to support maintenance beingdone.

4. Remove rings, metal watch bands, or any object which might short across the electrical circuit. Serious burnscan result, and equipment can be damaged, if this is not done.

TM 10-3930-255-20C 1

CHANGE HEADQUARTERSDEPARTMENT OF THE ARMY

No. 1 WASHINGTON, DC, 7 February 1980

Organizational Maintenance ManualTRUCK, LIFT, FORK, ELECTRIC, SOLID RUBBER TIRES, 2000 POUND CAPACITY, ARMYMODEL MHE-197, BAKER MODEL FTD-020-EE (NSN 3930-00-724-4058) (100-INCH LIFT),

(NSN 3930-00-965-0075) (130-INCH LIFT).

TM 10-3930-255-20, 22 April 1965, is changed as follows:Page 11. Add the following before paragraph 13:

WARNING

Insure that static electricity discharge straps are installed on the forklift truck and are in goodcondition. Failure to use the straps could result in the generation of a spark which could igniteexplosives or flammables.

By Order of the Secretary of the Army:

E. C. MEYERGeneral, United States Army

Official: Chief of Staff

J. C. PENNINGTONMajor General, United States Army

The Adjutant General

Distribution:To be distributed in accordance with DA Form 12-25A, Organizational maintenance requirements for Warehouse

Equipment.

}

TM 10-3930-255-20

TECHNICAL MANUAL HEADQUARTERSDEPARTMENT OF THE ARMY

No. 10-3930-255-20 WASHINGTON, D.C., 22 April 1965

Organizational Maintenance Manual

TRUCK, LIFT, FORK, ELECTRIC, SOLID RUBBER TIRES, 2,000-POUND CAPACITY,ARMY MODEL MHE-197, BAKER MODEL FTD-020-EE,

FSN 3930-724-4058 (100-INCH LIFT)FSN 3930-965-0075 (130-INCH LIFT)

Paragraph PageCHAPTER 1. INTRODUCTION

Section I. General ....................................................................................................... 1-5 2II. Description and data................................................................................... 6, 7 2, 4

CHAPTER 2. SERVICE UPON RECEIPT OF TRUCK..................................................... 8-10 6

CHAPTER 3. MAINTENANCE INSTRUCTIONS

Section I. Lubrication .................................................................................................. 11, 12 7II. Preventive maintenance services ............................................................... 13, 14 11, 13III. Troubleshooting .......................................................................................... 15, 16 13IV. Electrical system......................................................................................... 17-29 18-23V. Power axle .................................................................................................. 30 23VI. Rear axle..................................................................................................... 31-33 23-24VII. Brakes......................................................................................................... 34-39 24-27VIII. Wheels ........................................................................................................ 40-42 29-30IX. Steering....................................................................................................... 43-45 30-31X. Body and hood............................................................................................ 46-51 31-33XI. Hydraulic lift components............................................................................ 52-64 33-40XII. Electric motors ............................................................................................ 65-74 40-46

CHAPTER 4. SHIPMENT AND LIMITED STORAGE

Section I. Shipment within the Zone of Interior ........................................................... 75, 76 47, 48II. Limited storage ........................................................................................... 77, 78 50

APPENDIX I. REFERENCES .................................................................................................................. 53II. MAINTENANCE ALLOCATION......................................................................................... 54

INDEX ..................................................................................................................................................59-60

TAGO 8345A-750618-May 1965

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CHAPTER 1

INTRODUCTION

Section I. GENERAL

1. Scope

These instructions are published for the use ofpersonnel responsible for the organizationalmaintenance of Truck, Lift, Fork, Electric, Solid RubberTires, 2,000-Pound Capacity, Baker Model FTD-020-EE,Army Model MHE-197, Federal Stock No. 3930-724-4058 (100-inch lift), Federal Stock No. 3930-965-0075(130inch lift).

2. Appendixes

Appendix I is a list of current references. AppendixII is the maintenance allocation chart. The repair partsand special tools list authorized for use at organizationallevel is published in TM 10-3930-255-20P.

3. Maintenance Forms, Records, and Reports

The maintenance forms, records, and reports to beused in organizational maintenance of this truck arelisted and described in TM 38-750.

4. Reporting of Equipment Manual Improvements

The direct reporting of errors, omissions, andrecommendations for improving this manual by theindividual user is authorized and encouraged. DA Form2028 (Recommended Changes to DA Publications) willbe used for reporting these improvements. This form willbe completed in triplicate using pencil, pen, or typewriter.The original and one copy will be forwarded direct toCommanding General, U.S. Army Mobility EquipmentCenter, Attn: SMOME-MMP, 4300 GoodfellowBoulevard, St. Louis, Mo. 63120

5. Orientation

Throughout this manual, the terms right, left, front,and rear indicate directions from the viewpoint of theoperator sitting in the seat of the truck.

Section II. DESCRIPTION AND DATA

6. Description

a. General. Refer to TM 10-3930-255-10 for amore general description of the truck.

b. Truck. Power for travel and lifting is by a 36-voltbattery. The travel system includes motor, motorcontrols, and power axle assembly to provide fourspeeds forward and reverse. The truck may beequipped with either of two lift heights. Trucks rated for100-inch lift height are not fitted with overhead guardmentioned and shown in this manual. Liftingmechanisms are similar except for certain dimensionsfor each lift height. The lifting system includes an electricmotor, pump, controls, reservoir, lift and tilt cylinders,mast assembly, and forks. Hydraulic service brakes,and both hand and automatic parking brakes are used.

If the motor is reversed while the accelerator isdepressed, the circuit to the travel motor is broken. If themotor is reversed while traveling in first or in secondspeed, the vehicle will slow down, stop, and thenreverse.

c. Power Axle and Motor Assembly. The powertrain consists of the travel motor, coupling, power axlewith differential, axle shafts, final drive gears, andwheels. Power is transmitted direct from the travel motorthrough an adapter incorporating reduction gearing, to abevel ring gear and pinion in the axle, through the axledrive shafts, final drive gear and wheels.

d. Control System. The travel motor power andvehicle speed and direction are regulated by a systemwhich includes relays, an accelerating

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master switch, directional switch, and a tapped resistorproviding four speeds forward or reverse. A footaccelerator operates the accelerating master switch toselect, in sequence, any one of four speeds. Resistorsare used in the travel motor circuit to control speed oftruck.

e. Steering System. The steering system includesa recirculating ball type steering gear mounted at front oftruck, connected by a drag link to the steering bellcrank,tie rods, and steering knuckles, mounted on the trailingaxle.

f. Brake System. The brake system consists of amechanical parking brake and a hydraulic foot brake.The mechanical brake operates on a drum on the travelmotor armature shaft. This brake is applied either by ahandle on the steering column, or automatically throughspring action as the driver rises from the seat. Thehydraulic brake is a conventional automotive typesystem, effective only on the front (drive) wheels.

g. Mast Assembly. The mast assembly consists offour main assemblies as follows:

(1) Outer upright assembly. The outer uprightassembly is a welded one-piece assemblythat is mounted on the frame assembly andincloses the hoist cylinder and inner uprightassembly.

(2) Inner upright assembly. The inner uprightassembly is a welded one-piece assemblythat is mounted within the outer uprightassembly. The hoist cylinder, mounted inthe base of the outer upright assembly, issecured through the top of the inner uprightassembly. The inner upright assembly israised or lowered by action of the hoistcylinder.

(3) Crosshead assembly. The crossheadassembly is mounted over the hoistcylinder. Chains are attached to the liftcarriage assembly, roll over the crossheadassembly, and are secured to the hoistcylinder. As the cylinder rises, thecrosshead assembly rises, tightening thechains and raising the lift carriageassembly.

(4) Lift carriage assembly. The lift carriageassembly rides on four rollers within theinner upright assembly, which in turn slidesup and down inside of the outer uprightchannels. Two forks are mounted on thefront of the lift carriage assembly forhandling of loads.

h. Lift Hydraulic System. The hydraulic systemconsists of a reservoir, pump, control valve, hoist and tiltcylinder, and hydraulic hoses. The hoist cylinder raisesthe lift carriage and forks by hydraulic pressure suppliedby the pump. Gravity lowers the lift carriage.

i. Lift Cylinders. A compound lift is used on thisvehicle. ’The lift carriage rises to the top of the outerupright before the inner upright together with the liftcarriage move upward in the second stage. This isachieved by a dual hydraulic hoist cylinder. assemblywith two pistons working in sequence.

j. Tilt Cylinders. The tilt cylinders are double-acting. The uprights are tilted in and out by hydraulicpressure to the tilt cylinders.

k. Electrical System. The electrical system is atwo-wire, ungrounded type. The battery is connectedinto the circuit by means of a removable connector. Thecharging connection is also made through this connector.The weight of the operator in the driver’s seat closes thecircuit to the accelerating switch by an interlock switch.Travel control is through the accelerating switch, withcircuit made and broken by relay. The direction of travelis selected by the directional switch lever on the steeringgear post. Resistors in the motor armature circuit controlthe speed of the truck. The stop and taillight is inclosedin a guard on the rear of the truck. The headlight,mounted on the right side of the hoist upright, iscontrolled by a toggle switch on the instrument housing.

l. Battery. The 36-volt battery (Governmentfurnished equipment) used will weigh approximately1600 pounds. The inside of the truck batterycompartment is 281/2 inches long, 321/8 inches wide,and 243/8 inches high.

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m. Accelerator Master Assembly. The acceleratormaster assembly contains four sensitive switches,operated in sequence by cams. The cams are acuatedby the accelerator pedal. The switches energize relays,in the electrical equipment box, which select resistancesfrom taps to govern speed of the travel motor. Itprovides four individual speeds, and plugging control.The accelerating switch is located under the floor plate.

n. Directional Switch. The directional switchselects "forward" or "reverse" operation of the travelmotor. This switch is a three-position, manuallyoperated, two-circuit pilot device. The direction switch islocated on the steering gear post.

o. Relays. The relays make and break the circuitsin response to related manual and automatic controls.These relays are mounted in the electrical equipmentbox inside the cowl.

p. Travel Motor. The travel motor, under theoperator’s floor plate, is a series wound, direct currentelectric motor. Connected to the

power axle, it drives the truck forward or backward.

q. Hydraulic Pump Motor. The pump motor for theupright hydraulic system is controlled by a switch whichcloses the pump motor relay. The switch is operated byeither the lift control, or the tilt control, starting the motorwhen either lever is moved about one-quarter of its traveltoward lift or tilt position. The switch is opened when thelever is returned to neutral position. The pump motor isa series wound, direct current motor.

r. Resistors. The fixed, tapped resistor whichcontrols truck speed, is located in an inclosed box on theleft side of the truck. The travel motor controls select asmuch-resistance as required, ,by connecting sections ofthe resistor in series with the travel motor circuit.

s. Hourmeter. The hourmeter is the onlyinstrument used on this truck. This meter automaticallyrecords the number of hours truck has been in operation.

7. Tabulated Data

a. Electrical System.

Type................................................................................... Type EE, spark inclosed, two-wire,ungrounded.

Voltage .............................................................................. 36 volts deBattery ............................................................................... Government-furnished equipment.Traveling motor:

Current draw (empty) .................................................. 50 ampsCurrent draw (loaded) ................................................. 60 amps

Hydraulic pump motor:No load draw............................................................... 90 ampsFull load draw.............................................................. 150 amps

b. Manufacturer’s Identification.

Nomenclature .................................................................... Truck, lift, fork, electric.Manufacturer ..................................................................... Baker Industrial Trunks, Division of Otis

Elevator Company.Capacity............................................................................. 2,000 lbsModel................................................................................. FTD-020Contract number................................................................ DSA-4-020840-MP302Service weight ................................................................... 3,600 lbs (add 1,600 lbs for battery).Wheel load (no load on forks):

Drive wheels (total) ..................................................... 1,900 lbsSteering wheels (total) ................................................ 3,300 lbs

Center of gravity (no load on forks):Horizontal.................................................................... 27.3 in. from axle of drive wheels.Vertical ........................................................................ 13.7 in. above axle of drive wheels.

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c. General.

Vehicle capacity................................................................. 2.000 lbs at 24 in. load center.Maximum speed (empty)................................................... 5.0 mphMaximum speed (loaded).................................................. 4.8 mphGradeability ....................................................................... 15 percent with max load.

d. Shipping Dimensions. Refer to TM 10-4930-255-10.

e. Hydraulic System.

Main pump output.............................................................. 3.4 gpm (gallons per minute) at 1,000 psiand 1,200 rpm.

Relief valve setting ............................................................ 1,650 psiHoist speed (empty) .......................................................... 50 ft per minuteHoist speed (loaded) ......................................................... 35 ft per minute

f. Battery (Government-furnished equipment).

Voltage .............................................................................. 36 voltsType................................................................................... Lead-Acid or Nickel-Iron

g. Hydraulic Pump Motor.

Manufacturer . ................................................................... GEType................................................................................... BT

h. Control Valve.

Manufacturer ..................................................................... Hydraulic Unit Specialties Co.Model................................................................................. 3500-33

i. Directional Switch.

Manufacturer ..................................................................... Square D CompanyType................................................................................... CD-2AClass.................................................................................. 8963

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CHAPTER 2

SERVICE UPON RECEIPT OF TRUCK

8. General

When a new truck is received by an organization, itmust be serviced as described in paragraphs 9 and 10by organizational maintenance personnel.

9. Removal of Preservatives

a. Remove tape, paper, or other packing. Useextreme care when unpacking and installing separatelypackaged components.

b. Remove with SD (solvent, drycleaning)preservative compound from exposed metal surfaces.Because this compound is not a lubricant, take specialcare to see that it is completely removed from all wearingsurfaces.

c. Fill drive axle and hydraulic tank with

proper lubricant as indicated in lubrication order (para11).

d. Refer to direct support maintenance for batteryinstallation, and welding of battery retaining angles(shipped loose with new truck) to floor ’of batterycompartment.

10. Maintenance Inspection and Tests

a. The organization mechanic will perform theservices and tests that are listed and described in figure3. The services performed at this time will begin thecycle of regularly scheduled preventive maintenanceservices.

b. The deficiencies and shortcomings noted, andthe corrective action taken will be reported on theappropriate forms prescribed and explained in TM 38-750.

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CHAPTER 3

MAINTENANCE INSTRUCTIONS

Section I. LUBRICATION11. General

LO 10-3930-255-20 prescribes lubricationmaintenance of the truck; compliance with theinstructions is mandatory at all levels of maintenance.The order includes lubrication instructions for normal andabnormal conditions and temperatures. If a truck isreceived without a lubrication order, the using

organization must requisition a lubrication order throughnormal channels in accordance with AR 310-1

12. Illustrations

The lubrication order is illustrated in figure 1. Thenumbers that have been inserted on the border of theillustration refer to specific lubrication points that arepictured in figure 2 and called out by numbers 1 through22.

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Figure 1. LO 10-3930-255-20.TAGO 8345A

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Figure 1.-ContinuedTAGO 8345A

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Figure 2. Lubrication points.

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Section II. PREVENTIVE MAINTENANCE SERVICES

13. General

To insure that equipment is ready for operation atall times, it must be inspected systematically, so thatdefects will be discovered and corrected before theyresult in serious damage or failure. The necessarypreventive maintenance services to be performed arelisted in figure 3, and are described in paragraph 14.The item numbers indicate a convenient

sequence in which to perform the inspection. Note minordefects discovered during operation of the forklift truckfor future correction, to be made as soon as operationhas ceased. Stop operation immediately if a deficiencyis noted which would damage equipment if operationwere continued. All deficiencies and shortcomings willbe recorded, with corrective action taken, on DA Form2404, at the earliest possible opportunity.

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Figure 3. Quarterly preventive maintenance services.

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24

36-3926

12

14. Quarterly Preventive Maintenance Services

a. This paragraph contains an illustrated tabulatedlisting of preventive maintenance services which must beperformed by organizational maintenance personnel atquarterly intervals. A quarterly interval is equal to 3

calendar months, or 250 hours of operation, whicheveroccurs first.

b. The item numbers are listed consecutively andindicate the sequence of minimum requirements. Referto figure 3 for the quarterly preventive maintenanceservices.

Section III. TROUBLESHOOTING

15. General

This section provides information useful in diagnosingand correcting unsatisfactory operation or failure of theforklift truck and its components. Each trouble symptomstated is followed by a list of probable causes of the

trouble. The possible remedy recommended isdescribed opposite the probable cause. Any remedialaction required beyond the scope of organizationalmaintenance will be reported to direct supportmaintenance.

16. Troubleshooting Chart

(1) Truck will not start or develop full power.

a. Electrical.

Probable cause RemedyDead battery.......................................... Charge or replace (para. 28).Fusetron blown...................................... Replace (para. 69).Defective battery plug or receptacle...... Replace plug or receptacle (para. 20).Braided shunt in relay broken ............... Refer to direct support.Contacts dirty, worn, or broken in relay. Replace switch (para. 71), or refer to

or directional switch. direct support.Dirt in relay causing mechanical restric- Clean relay thoroughly.

tion.Mechanical binding in relay or accelera-Refer to direct support.

tor master assembly.Pole faces of plugging magnet not seal- Refer to direct support.

ing properly.Snap switches malfunctioning in accel-. Replace switches as necessary (para. 68).

erator master assembly.Seat switch not working......................... Adjust or replace switch (para. 36f).Open circuit due to loose connections in Clean and secure connections firmly (para.

accelerator master assembly. 68).

(2) All speeds not obtainable.

Probable cause RemedyOpen in relay main circuit...................... Refer to direct support.Object lodged in relay............................ Remove object.Dirty contacts on relay........................... Replace contacts (para. 67).Switches in accelerator master assembly Replace switches as necessary (para. 68).

malfunctioning.Sticking or binding of accelerator in any Refer to direct support.

part of stroke.

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(3) Overheating.Probable cause Remedy

Dirty relay contacts ............................... Replace contacts (para. 67).Broken, worn or ’improperly adjusted.. Refer to direct support.

brushes or brush holders in travelmotor.

Vehicle operating in low speed for pro- . No technical remedy. Advise operator tolonged periods. avoid practice if possible.

(4) Improper plugging control and timing through all speeds.Probable cause Remedy

Improper timing through all speeds....... Refer to direct support.Truck fails to leave first speed............... Refer to direct support.Shorted wires ........................................ Refer to direct support.Open relay in main circuit...................... Refer to direct support.Dirt in relay or directional switch............ Clean unit thoroughly.Dirty contact in relay or directional ...... Clean contacts.

switch.

b. Brakes.

(1) Brakes dragging.Probable cause Remedy

Plugged master cylinder compensating Open wheel cylinder bleeder fitting. Ifport. brakes release when fluid escapes, re-

place master cylinder.Seat brake improperly adjusted............. Adjust so that brake does not drag when

seat is down and is firmly applied whenseat is up (para. 36).

Mineral oil in brake system.................... Refer to direct support.

(2) Brake pedal goes to floor.Probable cause Remedy

Worn lining ............................................ Install new lined brakeshoes (para. 38).Air in system.......................................... Bleed system (para. 37b).Fluid low in master cylinder ................... Replenish fluid and check for leaks.Pedal improperly adjusted..................... Refer to direct support.

(3) Brake pedal under pressure gradually goes to floor plate.Probable cause Remedy

Leaks in hydraulic brake system ........... Locate and eliminate leaks.Scored master cylinder barrel or defec- Replace master cylinder (para. 39).

tive cup.

(4) Brake pedal has springy or rubbery action.Probable cause Remedy

Air in system.......................................... Bleed system (para. 37b).

(5) Weak braking action.Probable cause Remedy

Oil on linings.......................................... Replace brakeshoes (para. 38).Incorrect lining ....................................... Replace brakeshoes (para. 38).

(6) Harsh braking action.Probable cause Remedy

Brake lining grease or oil soaked .......... Replace brakeshoes (para. 38).Brake backing plate loose ..................... Refer to direct support.

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(7) Brake releases slowly.Probable cause Remedy

Hydraulic fluid congealed ...................... Drain, flush, and replace with properbrake fluid (para. 37b).

Retraction of brakeshoes restricted by Clean, adjust or replace as necessaryweak return springs or dirt (para. 38).Dirt in master cylinder............................ Replace master cylinder (para. 39).

(8) Truck pulls to one side.Probable cause Remedy

Brake lining grease or oil soaked .......... Replace brakeshoes (para. 38).

c. Steering. Difficult steering or wandering.

Probable cause RemedySteering gear adjustment too slack....... Readjust steering gear (para. 44).Damage drag link .................................. Refer to direct support.Defective steering gear ......................... Refer to direct support.

d. Hydraulic.

(1) Lift carriage will not lift load.Probable cause Remedy

Oil leaks in hoses .................................. Inspect fittings and couplings. Tighten orreplace as required.

Defective pump ..................................... Replace pump (para. 53).Fusetron blown...................................... Replace (para. 69).Defective control valve .......................... Replace valve.

(2) Load creeps down from raised position.Probable cause Remedy

Oil leak in lines ...................................... Tighten fittings.Leaky control valve................................ Tighten connections, replace valve if nec-

essary (para. 54).

(3) Hoisting speed erratic.Probable cause Remedy

Air in system.......................................... Bleed air from system by operation.Low level in reservoir............................. Fill reservoir to prescribed level (LO 10-

3930-255-20).

(4) Control valve plungers will not return to neutral.Probable cause Remedy

Sticking plungers ................................... Replace control valve (para. 54).Broken springs or dirt lodged in seats... Replace valve (para. 54).

(5) Forks uneven when load is lifted.Probable cause Remedy

Lift chains out of adjustment ................. Adjust so chain raises forks evenly (para.58).

(6) No motion of hydraulic unit when first started up.Probable cause Remedy

Oil supply in tank too low....................... Fill per LO 10-3930-255-20.Oil viscosity too heavy........................... Change to oil specified in LO 10-3930-

255-20.TAGO 8345A

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Probable cause RemedyAir leak in pump inlet line ...................... Tighten hose connection.Restricted pump ’inlet hose ................... Repair or replace (para. 53).Broken pump drive shaft, motor shaft ... Replace pump (para. 53) or motor (para.

or coupling ...................................... 66).Pump completely worn out .................... Replace pump (para. 53).Weak or broken relief valve spring........ Replace control valve (para. 54).Relief valve plunger stuck by dirt or ...... Replace control valve (para. 54).foreign matter.Pump rotating in wrong direction........... Refer to direct support.Insufficient pressure to start load .......... Refer to direct support.Truck overloaded................................... Reduce load.Failure at switch .................................... Replace switch.

(7) Loss of motion during operation.Probable cause Remedy

Loss of oil supply due to broken pump.. Replace hose (para. 61).inlet, outlet or cylinder connectinghoses or tank return hose.

(8) Slow motion.Probable cause Remedy

Pump wearing out ................................. Replace pump (para. 53).Pump rpm too slow................................ Replace pump motor (para. 66).Failure in hydraulic hoses...................... Replace hoses (para. 61).Relief valve plunger held partially off its Replace control valve (para. 53).

seat by dirt or foreign matter.Badly scored relief valve plunger or ...... Replace control valve (para. 53).

seat.Weak relief valve spring ........................ Replace control valve (para. 53).Aerated oil supply (foam in tank)........... Change oil (LO 10-3930-255-20).Oil too thin ............................................. See LO 10-3930-255-20 for proper grade.Oil supply too low .................................. Fill reservoir (LO 10-3930-255-20).Worn or scored piston packing ............. Refer to direct support.Bore of cylinder tube badly scored or.... Refer to direct support.

nicked.Cylinder misalignment ........................... Correct chain adjustment (para. 58).Mechanical obstruction of moving parts Remove obstruction.

(9) Jerky motion.Probable cause Remedy

Air in system.......................................... Bleed hydraulic system by operation.Cylinder misaligned due to structural .... Refer to direct support.

warpage.

(10) Speed or operation slow down after usage.Probable cause Remedy

Pump worn ............................................ Replace pump (para. 53).Improper oil used in system .................. See LO 10-3930-255-20 for proper grade.Dirt or foreign matter in system ............. Drain, flush out system, replace with new

oil.(11) Noisy operation.

Probable cause RemedyAir in hydraulic system........................... Bleed system by operation.Insufficient oil supply ............................. Fill reservoir (LO 10-3930-255-20).Pump worn out ...................................... Replace pump (para. 53).

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Probable cause RemedyAir leak ’in pump intake line................... Tighten hose.Misalignment between motor shaft and Tighten attaching parts.

pump drive shaft.Vibration of pump lines.......................... Secure lines.Chattering relief valve. Weak relief ... Replace control valve (para. 54).

valve spring.Incorrectly set relief valve pressure....... Replace control valve (para. 54).Broken or cracked gears in pump ......... Replace pump (para. 53).

(12) Oil heats up rapidly.Probable cause Remedy

Pump slippage, oil too thin .................... See LO 10-3930-255-20.Continued operation at relief valve pres- Check operation (TM 10-3930-255-10).

sure setting.Operating pressure is close to relief..... Check operation (TM 10-3930-255-10).

valve pressure setting.Operating at excessively high pressure Refer to direct support.Dirt oil .................................................... Change oil (LO 10-3930-255-20).Misalignment between pump drive shaft Tighten attaching parts.

and motor shaft.

(13) Hoist cylinder packing leaks.Probable cause Remedy

Defective hoist cylinder.......................... Refer to direct support.

(14) Hoist or tilt cylinder lowers or tilts while truck stands idle.Probable cause Remedy

Wrong packing ...................................... Refer to direct support.Worn or scored seals, packing or cylin- Refer to direct support.ders.Failure in hydraulic hose........................ Check, tighten or replace hose.

(15) Reservoir flows over.Probable cause Remedy

Excess oil in reservoir ........................... Check oil level with forks in lowered posi-tion and tilted back.

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Section IV. ELECTRICAL SYSTEM

17. General

This section presents instructions for organizationalmaintenance of the electrical system Figure 4 shows thelocation of components.

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Figure 4. Electrical system arrangement.

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18. Hourmeter

a. Removal.

(1) Remove two screws attaching instrumenthousing (fig. 4) to truck, and removehousing.

(2) Disconnect two leads at hourmeter, tapeends, and tag leads for identification.

(3) Remove two nuts holding hourmeter toinstrument housing, and lift hourmeter outof housing.

b. Installation. Reverse procedures in a above.

19. Light Switch

a. Removal.

(1) Remove two screws attaching instrumenthousing (fig. 4) to truck, and removehousing.

(2) Remove nut at top of light switch and lowerswitch out bottom of instrument housing.

(3) Disconnect, tape, and tag leads fromswitch.


20. Battery Connector Receptacle

a. Removal.

(1) Remove four screws shown in figure 5.

(2) Disconnect leads shown, inside electricalequipment box, and draw them out.Remove receptacle with leads.


21. Stoplight Switch

Before replacing switch, check that it is trulydefective, and not merely in need of adjustment, and thatleads are correctly installed as in a above.

a. Inspection and Test.

(1) Remove floor plate (para 50).(2) Inspect that wires labeled (+) and (33) to

switch (fig. 6) are connected to terminalsmarked "A" and wires (9) and (10) areconnected to "B" terminals. If not, connectthem correctly before proceeding.

(3) Connect a voltmeter lead to each "A"terminal, and operate switch button byhand. If meter reads system voltage withbutton free, and zero voltage with buttonpressed, switch is operative. Test at "B"terminals for opposite results. Continue to(4) below.

(4) With voltmeter still connected as in (3)above, operate pedal manually. Ifoperation of pedal does not give sameresults, switch position must be adjusted sobrake application closes switch at "A"terminals and opens switch at "B"terminals, reversing this on releasing brakepedal.

Figure 5. Battery connector receptacle. Figure 6. Stoplight switch.

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b. Adjustment. Disconnect leads, and loosen twonuts shown in figure 6. Adjust switch position by turningit in or out of threaded hole in bracket so switch lightsstoplight before braking action begins, and light goes outbefore pedal reaches top of travel. Tighten nuts.

c. Removal.

(1) Remove floor plates (para 50).(2) Remove outermost nut (fig. 6) and leads,

and unscrew switch from bracket.

d. Installation. Reverse procedures in c above andadjust switch (b above).

22. Headlight

a. Removal.

(1) Remove clamps (fig. 7) holding conduit toouter upright.

(2) Disconnect two wires at terminals at bottomend of conduit.

(3) Remove two screws, nuts and washersattaching light to upright and remove lightand conduit as an assembly.

Figure 7. Headlight, installed.

b. Repair. Repair of headlight is confined toreplacing the sealed beam lamp (para 24).

c. Installation. Reverse procedures in a above.

23. Stop and Taillight

a. Removal.

(1) Remove two screws, nuts, and washers(fig. 8) attaching guard to truck. Lift guardand disconnect light wires from terminalboard under guard.

(2) Remove screws holding screen to guardand remove screen.

(3) Remove nut and washer holding lightassembly to guard, and remove guard.

Figure 8. Stop and taillight, installed.

b. Repair. Remove bezel and lens, and install newbulb. Replace bezel and lens.

c. Installation. Reverse procedures shown in aabove.

24. Lamps

a. Headlight Lamp Replacement.

(1) Remove bezel from headlight.(2) Withdraw sealed beam unit from headlight

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(3) Install by reversing procedures in (1) and(2) above.

b. Stop and Taillight Lamp Replacement. Seeparagraph 23b.

25. Taillight Resistor

a. Removal.

(1) Remove electrical equipment box cover (fig.4).

(2) Disconnect wires numbered 32 and 33 fromresistor, located at center of box, on board.Remove two mounting screws and removeresistor.

b. Test. Test resistor with ohmmeter acrossterminals for 40 ohms resistance, plus or minus 20%.


26. Horn

a. Removal.

(1) Remove truck floor plate (para 50).(2) Disconnect wires (fig. 9) from horn.(3) Remove screws holding horn to adapter

and remove horn.

Figure 9. Horn, installed.


27. Horn Button

a. Removal. Remove four screws (fig. 10) and liftoff retainer, cap, separator, insulator, contact, andspring.

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Figure 10. Horn button, cutaway view.


28. Battery

a. Service. Refer to TM 10-3930-255-10, and TM10-1690A.

b. Removal.

(1) Open battery compartment, and disconnectbattery leads from truck at receptacle (TM10-3930-255-10).

(2) With a hoist rated at more than 2,000-pounds capacity, lift battery from truck byhooks through the lifting eyes at each sideof battery.

Caution: Use spreader bar aswide as battery between lifting hooksto avoid inward pull on battery case.Keep personnel at a distance duringremoving operation to minimize riskfrom electrolyte spillage.

c. Installation. Reverse procedures in b above.

29. Headlight, Stop and Taillight Wiring HarnessRepair

Wiring to these lights is contained in flexible metalconduit. It is not practical to repair this wiring. Ifdamaged, refer to direct support maintenance forreplacement.

Section V. POWER AXLE

30. Power Axle Service

All organizational level service of the power axle is given in LO 10-3930-255-20.

Section VI. REAR AXLE

31. General

Since the rear axle provides steering for the truck, it isfunctionally associated with the

steering gear. Maintenance at organizational level islimited to adjustment of the tie rods for toe-in. Relatedsteering gear adjustments will be found in paragraph 44.

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32. Adjustment of Wheel Alignment

a. Measurement. Determine if wheel alignmentadjustment is needed, as follows:

(1) With rear axle (fig. 11) level, front to rear,and wheels in straight ahead position,measure inside span between tires at hubheight at front of axle.

(2) Repeat (1) above at rear of axle.(3) If measurements obtained in (1) and (2)

above differ by over 1/16 inch, adjust asgiven in b below until wheels are parallel towithin 1/16 inch as measured in (1) and (2)above.

Figure 11. Steer axle, adjustment points.

b. Adjustment.

(1) Loosen (but do not remove) screws and nutsthrough all tie rod end clamps (fig. 11).

(2) Turn each tie rod an equal number of turnsin the direction necessary to change toe-inas required. Each tie rod has right-handthreads at one end, left-hand threads at theother, so adjustment can be made tochange effective length without dismountingtie rod.

(3) When adjustment has been completedtighten tie rod clamp screws and washers.

33. Steering Knuckle Service

All steering knuckle service allocated to operationalmaintenance is given in LO 10-3930-255-20.

Section VII. BRAKES

34. General

This section contains organizational maintenanceinstructions for the mechanical (parking) and hydraulic(service) brake systems used on the truck.

35. Handbrake Lever

a. Removal.

(1) Release handbrake, and remove screws,nuts, and washers which attach handbrakelever (fig. 12) to bracket on steeringcolumn.

(2) Remove cotter pin and clevis pin attachinghandbrake cable assembly to handbrakelever, and remove lever.

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Figure 12. Service and parking brake controls.


36. Brake Cable and Brake Rod

a. Cable Removal.

(1) Remove handbrake lever (para 35a).(2) Loosen two nuts holding cable to slotted

bracket on steering column and slide cablefrom slot.

(3) Remove screws, nuts, washers, and

two clamps holding cable assembly to truckframe.

(4) Remove pin and cotter pin attaching cableto ofiset yoke, loosen two nuts at slottedbracket on truck frame (lower end of cable),and remove cable assembly from truck.

b. Cable Installation. Reverse procedures in aabove.

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c. Cable Adjustment. Position cable housing byadjusting nuts at both slotted brackets until brakereleases fully, and locks in applied position with a definitesnap action.

d. Brake Rod Removal.

(1) Run down large nut (fig. 12) under spring,until spring tension is relieved.

(2) Drive out roll pin and remove pin from eyeat top of brake rod.

Warning: Be sure spring tensionis relieved before removing pin.

(3) Loosen jamnut on lower end of brake rod atyoke, unscrew rod from yoke and removerod with striker, spring, and spacer attached.

e. Brake Rod Installation. Install spacer, spring,striker, and nuts as shown in figure 12, on rod, andreverse procedures in d above.

f. Brake Rod Adjustment. After installation,perform the following:

(1) Adjust spring tension raising seat to suitoperator, by turning large nut beneathspring.

(2) Adjust position of motor switch striker, withseat bottomed as by operator’s weight, somotor switch is definitely actuated. Run twostriker jamnuts up or down rod to positionstriker.

37. Service Brake

a. Brake Adjustment. The service brakes are self-adjusting to take up play due to lining wear. Refer toparagraph 39b for pedal adjustment.

b. Bleeding Service Blake System. The hydraulicbrake system must at times be bled to expel air in thesystem. The need is generally indicated by springy orspongy brake pedal action. Unless special brakebleeding equipment is available, two men are required tobleed the system, one to maintain a constant supply offluid in the master cylinder and to pump the brake pedal,the other to perform the bleeding operation.

(1) Remove filler plug from master cylinder andfill with hydraulic brake fluid.

(2) Clean bleeder screws at each wheelcylinder (fig. 13). Remove small screwsfrom bore of bleeder screws. Attach oneend of bleeder hose to bleeder screw andplace other end of hose in clean containerpartially filled with hydraulic brake fluid. Besure end of hose is submerged in thehydraulic fluid.

(3) Turn bleeder screw counterclockwise three-quarters of a turn. Apply steady pressure to.brake pedal. Hydraulic fluid containing airbubbles should be forced through bleederhose into container.

(4) Maintain fluid level in master cylinder andcontinue to operate brake pedal until fluidflows in a steady solid stream without airbubbles. Close bleeder screw by turning itclockwise. Remove bleeder hose, andreplace small screw in bleeder screw.

(5) Repeat bleeding procedure at other wheel,replenishing brake fluid in master cylinderbefore each wheel cylinder before eachwheel cylinder is bled. Replace filler plug inmaster cylinder.

Caution: Hydraulic brake fluidfrom the brake system must not bereused.

Figure 13. Brake bleeding points.

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38. Brakeshoes

a. Removal.

(1) Remove front wheels (para 41).(2) With brake spring pliers, remove

brakeshoe return spring (fig. 14) andretainer spring. Carefully removebrakeshoes, and install brake clamps onwheel cylinder to prevent pistons beingpushed out of cylinder by residual pressurein brake lines.

Figure 14. Brakeshoe removal.

b. Installation.

(1) Reverse procedure in a(2) above.(2) Temporarily adjust shoes inward as far as

they will go. This procedure consistsessentially of tapping self-adjuster leverstoward center of axle.

(3) Install front wheels (para 41) and operatebrake pedal several times to adjust brakes.

39. Master Cylinder

a. Removal.

(1) Remove floor plate (para 50).(2) Remove hollow bolt (fig. 15) and brake line

fitting from front of master cylinder. Takeprecautions to keep dirt from entering brakeline.

(3) Remove nuts, washers, and screwsattaching master cylinder to truck, andremove master cylinder. Push rod willremain connected to brake shaft and neednot be removed.

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Figure 15. Master cylinder.

b. Installation.

(1) Reverse procedures in a above.(2) Fill cylinder with brake fluid (LO 10-3930-

255-20).(3) Bleed brake hydraulic system (para 37b).

(4) Loosen jamnut on push rod, and adjustlength of push rod to give 1/4-inch to 5/8-inch free travel of pedal before brakeapplication begins. Tighten jamnut tosecure adjustment.

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Section VIII. WHEELS40. General

This section contains instructions for replacement of thetruck wheels, and service and replacement of rear wheelbearings. Refer service other than this to highermaintenance level.

41. Wheels

a. Front Wheel Removal.

(1) Jack up front wheels as follows:

(a) Tilt mast to extreme back position.

(b) Place block directly under mast at liftcylinder.

(c) Tilt mast forward until wheels are clear.

(2) Remove six screws (fig. 16) holding wheelto truck.

(2) Remove wheel.

Note. If brake lining drags on wheel,interfering with removal, slack offadjustment of brake self-adjusters byvigorously wiggling wheel to forcebrakeshoes inward.

Figure 16. Front wheel removal.

b. Front Wheel Installation. Reverse procedures ina above.

c. Rear Wheel Removal.

(1) Lower forks fully and tilt mast back. Raiserear of truck until wheels clear floor.

(2) Remove hub cap (fig. 17), and removecotter pin, nut, and washer from bore ofwheel.

(3) Draw wheel from steering axle spindle.Because of manufacturing tolerances thecone and rollers of the inboard bearing mayremain with spindle. If so, it can easily beremoved. Avoid damaging oil seal, ifpossible, when removing wheel.

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Figure 17. Rear wheel removal.

d. Rear Wheel Installation. Reverse procedures inc above, tightening wheel nut snug, then backing it offnot more than 1/6 turn, and install cotter pin.

42. Rear Wheel Bearings

a. Removal.

(1) Remove rear wheels (para 41c).(2) Pull bearings from bore of wheel. A slip

hammer bearing puller may be used to pullbearings from wheel if they stick in bore.

(3) Remove retaining rings which position

bearings.

b. Service.

(1) Clean bearings with SD and dry thoroughly.(2) Inspect cups and rollers for wear or failure.

Inspect cone and roller assemblies forroughness when rotated.

(3) If bearings are serviceable, repack withgrease in accordance with LO 10-3930-255-20, using a bearing packing device, ifavailable.


Section IX. STEERING

43. General

This section contains organizational maintenanceinstructions for the steering gear and linkage to thesteering axle. Service according to the instructions in LO10-3930-255-20.

44. Steering Gear Assembly

a. Lash Adjustment.

(1) Remove nut (fig. 18) holding drag link topitman arm, and disconnect drag link.

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Note. If necessary, use puller, butdo not damage threads, or placestrain on pitman arm.

(2) Loosen jamnut and turn lash adjuster

with screwdriver until steering wheel passes throughcenter of travel with 14 to 18 ounces pull on the rim.Tighten jamnut, and install drag link.

Figure 18. Steering adjustment.

b. Steering Linkage Adjustment.

(1) With steering wheel halfway betweenextreme right and extreme left turn,assembly pitman arm to steering gear asshown in figure 18.

(2) With trailing axle wheels in straight aheadposition, adjust drag link to proper length byloosening clamps and turning drag linktubing until tie rod end at front of drag linkwill enter hole in pitman arm freely, withpitman arm vertical.

(3) Tighten clamps.

45. Steering Wheel

a. Removal.

(1) Remove horn button assembly (para 27a).(2) Remove nut (fig. 10).(3) With a steering wheel puller, draw wheel

from shaft.

Caution: Do not try to remove wheelwithout proper puller, as the steeringgear could be damaged.


Section X. BODY AND HOOD

46. General

This section contains maintenance instructions forexterior structural components, and the seat of the truck,within the scope of organizational maintenance.

47. Battery Box Top Cover

a. Removal.

(1) Remove taillight and taillight guard as anassembly (para 23a(1)).

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(2) Remove screws and nuts (fig. 19) whichattach cover hinge to truck, and lift offcover.

Figure 19. Battery box top cover and overhead guard.


48. Battery Box Side Covers

a. Removal. Pull open side cover to be removed,remove nuts and screws (fig. 19) attaching side cover totruck, and remove cover.


49. Overhead Guard (Used on Trucks With 130-InchLift Only)

a. Removal. Remove screws (fig. 19) at eachupright bore of guard, and lift guard from truck.


50. Floor Plate

a. Removal.

(1) Unhook cowl latches (fig. 20) and lift cowlfree of truck.

(2) Remove two screws at front of floor plate,and lift off floor plate.

Figure 20. Floor plate removal.

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51. Seat Assembly

a. Removal. Remove four screws, nuts, andwashers (fig. 21) which attach assembly to brakeactuating bar. Remove seat from truck.

Figure 21. Seat.

b. Disassembly. Remove wood screws holdingbackrest to frame and remove backrest. Remove nutsand washers holding seat cushion to frame. Do notdisassemble guide rails.

c. Repair. Repair slightly damaged (torn)upholstery material according to good commercialpractice, by sewing, or adhesive patch. If wear ordamage is extensive, replace entire cushion:

d. Assembly. Reverse procedure in b above.

e. Installation. Reverse procedure in a above.

Section XI. HYDRAULIC LIFT COMPONENTS

52. General

This section contains instructions for organizationalmaintenance of the hydraulic and mechanical itemsrelated to the lift mechanism, including controls.

53. Hydraulic Pump Assembly

a. Removal.

(1) Remove floor plate (para 50).(2) Position a bucket under pump (fig. 22) to

catch draining oil, and disconnect hoseelbow fittings at pump. Remove hosesfrom pump and cap ends.

(3) Remove two screws attaching pump tomotor. Remove pump.

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Figure 22. Hydraulic pump and motor.


54. Control Valve

a. Removal.

(1) Remove cowl (para 50a).(2) Remove one cotter pin and clevis pin (fig.

23) from links at each lever, disconnectinglevers from valve plungers.

(3) Disconnect four hoses equipped with elbowfittings, remove hose clamp, and removelast hose.

(4) Remove three nuts, screws, and washersattaching valve and mounting plate to truck,and remove valve. Cap or plug hoses andparts of valve.

(5) Remove screws, nuts, and washers holdingswitch bracket to mounting plate, andremove switch bracket, with switchattached.

(6) Remove screws, nuts, and washers, andremove mounting plate from valve.

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Figure 23. Control valve.


55. Control Valve Levers

a. Removal.

(1) Perform procedures in paragraph 54a(1)and (2).

(2) Remove cotter pins from pin on whichhandles pivot (fig. 23) and withdraw pin,removing three spacer washers as

pin is drawn out of levers and bracket.

(3) Lift off levers.


56. Control Valve Mounting Plate

a. Removal. Refer to paragraph 54.

b. Installation. Reverse procedures in paragraph54a, turning switch in or out of switch bracket andposition so that levers will actuate it when operated.

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57. Tilt Cylinders

a. Removal.

(1) Disconnect hoses (fig. 24) from tilt cylinder.Cap hoses and plug ports in cylinder toexclude dirt.

(2) Remove screws, nuts, and washersattaching plates to brackets on truck frameand on uprights. Remove plates fromnotches in pins.

(3) Pull or drive pins from brackets and tiltcylinder ends. Be careful not to let cylinderfall as pins come out.

Figure 24. Tilt cylinder.

b. Installation. Reverse procedures in a above.After installation, operate tilt control several times topurge air from cylinder. Check cylinder and hose fittingsfor leakage while operating.

58. Crosshead Rollers

a. Removal.

(1) Lower carriage fully, remove nuts (fig. 25)from chain adjusting screws, and lay chainsback out of way.

(2) Remove retaining rings, washers, rollers,and bushings from crosshead.

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Figure 25. Crosshead, rollers, and chains.

b. Installation.

(1) Reverse procedures in a above.(2) Adjust nuts on chain adjusting screws (fig.

25) so each chain begins lifting at sametime.

Caution: If load is not sharedequally by chains, first chain to beginlifting will cock crosshead and causerapid wear and damage to liftcylinder.

59. Chain Assemblies

a. Adjustment. Refer to paragraph 58b(2).

b. Removal.

(1) Refer to paragraph 58a(1).(2) Unhook chains from carriage assembly.


d. Repair. Repair is limited to replacing damagedlinks.

(1) Remove chain from truck (b above).(2) With a chain breaking tool, remove

damaged link or links from chain. Failure ofone link may damage adjacent links.Remove all damaged links.

(3) Install replacement link and rivet pin end tosecure side plates of chain.

Note. Plates of end links are securedby cotter pins. Do not rivet or peenthese pins.

60. Forks

a. Removal.

(1) Lower carriage fully, and lift load backrestfrom carriage (fig. 26).

(2) Lift spacers from carriage. Removescrews, washers, and one plate fromcarriage. Hold forks so they don’t fall anddraw shaft from carriage. Forks are nowfree. Remove them.

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Figure 26. Fork removal.


61. Tilt and Lift Cylinder Hoses

a. Removal.

Note. Cap or plug open hoses andports to exclude dirt.

(1) Remove floor plate (para 50).(2) Disconnect hose or hoses to be removed at

control valve (fig. 23).(3) Disconnect tilt cylinder hoses from valve at

tees in lines to tilt cylinders. If these hosesare to be removed, take them off of truck atthis point.

(4) Disconnect hoses at tilt cylinders. Removenuts and washers holding tee fittings in tiltcylinder lines to bracket (fig. 27) andremove hoses from truck.

(5) Disconnect lift cylinder hose at flowrestrictor (fig. 27) and remove hose.

Figure 27. Hose removal.

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b. Installation. Reverse procedures in a above.Actuate lift and tilt systems for several cycles withoutload to bleed units of air.

62. Filter Cartridges

Two filters are used in the hydraulic system; one insuction line to pump, within the tank, the other in returnline from control valve, at left rear of tank.

a. Suction Filter Cartridge Replacement.

(1) Remove four screws and washers (fig. 28)and lift off cover and gasket.

(2) Lift out used cartridge and install newcartridge.

(3) Reverse procedure in (1) above.

Figure 28. Suction filter.

b. Return Filter Cartridge Replacement.

(1) Turn cartridge (fig. 29) from filter cover byhand.

(2) Install new cartridge by reversing procedurein (1) above.

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Figure 29. Return filter.

63. Oil Tank

Service according to LO 10-3930-255-20.

64. Oil Breather Cap

To clean, remove cap (fig. 28) by lifting it off, cleanthoroughly with SD, and replace.

Section XII. ELECTRIC MOTORS

65. General

This section contains instructions for the pumpmotor, power steering motor, and such other electricalitems as are within the scope of organizationalmaintenance.

66. Pump Motor

a. Removal.

(1) Remove floor plate (para 50).(2) Remove pump (para 53).

Note. Leave hoses connected topump.

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(3) Disconnect wires at terminals (fig. 30),remove nuts and screws through strapholding motor. Remove screw and clamp(fig. 4) holding thermal relay to motor andremove thermal relay. Remove motor.

(2) Note free running current draw of motor.Draw should not exceed 90 amperes at 36volts. Motor should run freely and quietly.

Figure 30. Pump motor.

b. Test.

(1) With motor removed from truck (or whilepump is removed from motor), makeconnections to motor, as shown in figure31.

Caution: Hold motor securelyagainst starting torque action.

Figure 31. Motor test, organizational maintenance.


67. Master or Auxiliary Control Relay Repair

Organizational maintenance of these relaysconsists only of replacement of the contacts, when thesilver has worn almost down to the steel support.

a. Remove cowl (para. 50a(1)), and remove twelvescrews securing cover of electrical equipment box (fig.4).

b. Remove contact to ,be replaced by removing nut(fig. 32) on that contact and lifting contact free of relay.

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Figure 32. Contact replacement.

c. Install new contact by reversing procedures in aand b above.

68. Accelerator Master Assembly

a. Removal.

(1) Disconnect linkage from operating lever(fig. 33), remove cover screws, andremove cover.

(2) Disconnect leads inside housing at switchterminal screws (fig. 34). Carefully drawleads out through conduit fitting. Do notremove identification labels from leads.

(3) Remove screws holding base of housing totruck and remove assembly.

Figure 33. Accelerator master assembly, installed.

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Figure 34. Accelerator master assembly, interior view.

b. Repair. The following procedure does notrequire removal of the assembly.

(1) Remove truck floor plate (para 50).(2) Remove cover screws and cover (fig. 33).(3) Disconnect leads at switch to be replaced,

remove switch holddown screws, andremove switch.

(4) Install new switch by reversing proceduresin (1) to (3) above.

c. Installation. Reverse procedures in a above,dressing leads neatly, as shown in figure 34.

Connect leads according to the numbers, in thearrangement illustrated in figure 34.

69. Fusetrons

a. Removal.

(1) Remove hood (para 50a(1)).(2) Remove screws and cover plate at top right

end of electrical equipment box (fig. 4), toexpose fusetrons and fuses (fig. 35).

(3) Remove nuts at each end of fusetron to bereplaced, and remove fusetron.

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Figure 35. Fusetrons and fuses.


70. Fuses

a. Removal.

(1) Refer to paragraph 69a (1) and (2).(2) Pull fuse to be replaced straight up from

fuse holder.


71. Directional Control Switch

a. Removal.

(1) Remove two cover screws and cover (fig.36). Disconnect and tag leads inside controlswitch.

(2) Disconnect conduit at fitting. Draw leadsfrom control switch.

(3) Remove four clamp screws, clamp, andcontrol switch.

Figure 36 Directional control, right and left views.

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b. Installation. Reverse procedures in a above,installing leads to terminals from which they wereremoved.

72. Pump Motor Switch

a. Removal.

(1) Remove cowl (para 50a(1)).(2) Disconnect leads at switch (fig. 23), loosen

jamnut, and screw switch out of switchbracket.

b. Installation. Reverse procedures in a above,turning switch in to point where levers actuate it.

73. Speed Resistor

This is a two part unit with several taps.

a. Test.

(1) Disconnect and tag leads at resistor taps(fig. 37).

(2) With ohmmeter, measure resistancesbetween taps for values displayed in figure38.

Figure 37. Speed resistors, installed.

Figure 38. Speed resistor test values.TAGO 8345A

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b. Removal.

(1) Perform procedure in a(1l) above.

(2) Remove nuts and washers at end ofresistor and lift resistor from truck.


74. Thermal Relay

Each motor is protected by a thermal relay which willopen the motor circuit if overheating occurs. Whentemperature sensed by the relay drops to a safeoperating value, the relay will automatically close.

a. Removal.

(1) Remove screw and clamp (fig. 4) whichfastens relay to motor and lift relay frommotor.

(2) Scrape sealing compound from relayterminals. Unsolder leads at terminals.

b. Installation. Reverse procedures in a above,soldering leads to terminals with rosin flux and solder.Avoid unnecessary heating of the relay while soldering.Coat terminals after soldering with silicone rubbersealing compound.

c. Test.

(1) Test electrical continuity of relay betweenterminals with an ohmmeter or test light.Test at room temperature.

(2) If controlled temperature is available, testopening temperature of relay. It shouldopen on rising temperature at 224°F., plusor minus 4°.

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CHAPTER 4

SHIPMENT AND LIMITED STORAGE

Section I. SHIPMENT WITHIN THE ZONE OF INTERIOR

75. Preparation of Equipment for Shipment

a. General. Detailed instructions for thepreparation for domestic shipment are outlined within thisparagraph. Preservation will be accomplished insequence that will not require the operation of previouslypreserved components.

b. Inspection. Equipment will be inspected for anyunusual conditions such as damage, rusting,accumulation of water, and pilferage. Utilize theinspection criterion provided on the quarterly preventivemaintenance services (para 14), to execute DA Form2404 on the lift truck, as applicable.

c. Cleaning and Drying. Clean and dry the lift truckby an approved method. Approved methods of cleaning,drying, types of preservatives, and methods ofapplication are described in TM 38-230.

d. Painting. Paint all surfaces where the paint hasbeen removed or damaged. Refer to TM 9-213 fordetailed cleaning and painting instructions.

e. Sealing of Openings. Openings that will permitdirect entry of water into the interior of the electric motorswill be sealed with pressure sensitive tape conforming toSpecification PPP-T-60, type III, class 1.

f. Hydraulic Control Systems, Except HydraulicBrakes.

(1) Fully retract the lift and tilt pistons as far asthe linkage will permit, and secure.

(2) Coat exposed portions of the hydraulicpiston rods and operating valve controlswith type P-6 preservative conforming toSpecification MIL-C-11796, class 3.

(3) Wrap with type I, class 2, grade A, barriermaterial conforming to MIL-B-121B.

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(4) Secure the hydraulic operating valvecontrols in a neutral position.

g. Exterior Surfaces. Coat exposed machineferrous metal surfaces with preservative (P-6)conforming to Specification MIL-C-11796, class 3. Ifpreservative is not available, use automotive and artillerygrease as specified on the lubrication order.

h. Marking. Marking will conform to MIL STD-129.

i. Seat Backs and Cushions. Wrap seat backsand cushions in a waterproof barrier material and sealthe seams with type III, class 1, pressure-sensitive tapeconforming to Specification PPP-T-60.

j. Batteries and Cables. The battery (if installed)will be dry and fully charged and secured in the batterycompartment. Cables will be disconnected, ventholessealed, and all terminals wrapped and secured with typeIII, class 1, pressure-sensitive tape conforming toSpecification PPP-T-60.

k. Disassembly, Disassembled Parts, and BasicIssue Items.

(1) Disassembly will be limited to the removalof parts and projecting components thattend to increase the overall profile of theequipment and that which is subject topilferage.-

(2) Disassembled items will be packed with thepublications, in a suitable container andsecured to the equipment to prevent loss orpilferage. Refer to TM 38-230 for selectionand fabrication of containers.

(3) Forks will be detached and securelystrapped to the mast or other suitable partof the truck in such a manner as not tocause damage or increase the

47

cube unnecessarily. Flat steel strappingnot less than 11/ inch by 0.035 inch will beused.

76. Loading Equipment for Shipment, Rail or Truck

This paragraph outlines the requirements forloading and blocking truck. A flatcar is illustrated;however, if shipment is by truck or box-car, adapt theseinstructions to suit the carry-

ing vehicle with no more than essential deviations.

a. Loading.

(1) Lift truck onto flatcar with a hoist rated at 4tons or greater, or

(2) Construct a ramp as shown in figure 39 anddrive or pull truck up ramp.

Caution: Be very careful abouttipping on ramp.

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Figure 39. Loading truck for shipment.

49

b. Blocking. Block, strap, and tie down truck as shown in figure 39.

Section II. LIMITED STORAGE

77. Preparation of Equipment for Limited Storage

a. General. Detailed instructions for preservingand maintaining equipment in limited storage areoutlined in this paragraph. Limited storage is defined asstorage not to exceed 6 months. Refer to AR 743-505.

b. Inspection. Equipment will be inspected for anyunusual conditions such as damage, rusting,accumulation of water, and pilferage. Utilize theinspection criterior provided on the quarterly preventivemaintenance services (para 14) to execute DA Form2404 on the lift truck, as applicable.

c. Cleaning and Drying. Clean and dry the lift truckby an approved method. Approved methods of cleaning,drying, types of preservatives, and methods ofapplication are described in TM 38-230.

d. Painting. Paint all surfaces where paint hasbeen removed or damaged. Refer to TM 9-213 fordetailed cleaning and painting instructions.

e. Sealing of Openings. Openings that will permitdirect entry of water into the interior of the electric motorswill be sealed with pressure sensitive tape, conforming toSpecification PPP-T-60, type III, class 1.

f. Hydraulic Control Systems, Except HydraulicBrakes.

(1) Fully retract the piston as far as the linkagewill permit and secure.

(2) Coat exposed portions of the hydraulicpiston rods and operating valve controlswith type P-6 preservative conforming toSpecification MIL-C-11796, class 3.

(3) Wrap with type I, class 2, grade A, barriermaterial conforming to Specification MIL-B-121B.

g. Exterior Surfaces. Coat exposed machine

ferrous metal surfaces with preservative (P-6)conforming to Specification MIL-C-11796, class 3..Ifpreservative is not available, use automotive and artillerygrease as specified ’on the lubrication order.

h. Seat Backs and Cushions. Wrap seat backsand cushions in a waterproof barrier material and sealthe seams with type III, class 1, pressure-sensitive tapeconforming to Specification PPP-T-60.

i. Batteries and Cables. The battery will besecured in the battery compartment. The battery will befilled and fully charged. Cables will be disconnected,ventholes sealed, and all terminals wrapped and securedwith type III, class 1, pressure-sensitive tape conformingto Specification PPP-T-60.

j. Disassembly, Disassembled Parts, and BasicIssue Items.

(1) Disassembly will be limited to the removalof parts and projecting components thattend to increase the overall profile of theequipment and that which is subject topilferage.

(2) Disassembled items will be packed with thepublications in a suitable container andsecured to the equipment to prevent loss orpilferage. Refer to TM 38-230 for selectionand fabrication of containers.

k. Weatherproofing. Warehouse storage ispreferred for the truck. If this is not available, select afirm, level, well-drained location. Place truck on heavyplanking or other solid surface. Cover truck withtarpaulin or other waterproof material and tie downsecurely.

78. Inspection and Maintenance of Equipment inStorage

a. Inspection. When equipment has been placed inlimited storage all scheduled preventive maintenanceservices, including inspection,

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will be suspended and preventive maintenanceinspection will be performed as specified herein. Referto AR 743-505.

b. Worksheet and Preventive Maintenance.Applicable forms listed in TM 38-750 will be prepared foreach major item of equipment every 90 days while inlimited storage. Perform

required maintenance promptly to make sure equipmentis mechanically sound and ready for immediate use.

c. Operation. Operate equipment in limited storagelong enough to insure complete lubrication of allbearings, gears, and the like, every 90 days. Equipmentmust be serviced and in satisfactory condition before it isoperated.

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THIS PAGE LEFT BLANK INTENTIONALLY

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APPENDIX I

REFERENCES

AR 320-5 Dictionary of United States Army TermsAR 320-50 Authorized Abbreviations and Brevity CodesAR 700-58 Report of Damaged or Improper ShipmentAR 700-3900-5 Registration of Materials Handling Equipment and Special Purpose

VehiclesAR 746-5 Color and Marking of Army MaterielAR 750-3900-1 Materials Handling EquipmentAR 750-5 Organization, Policies, and Responsibilities for Maintenance OperationsDA Pam 108-1 Index of Army Motion Pictures, Film Strips, Slides, Tapes, and Phono-

RecordingsDA Pam 310-1 Military Publications: Index of Administrative PublicationsDA Pam 310-2 Military Publications: Index of Blank FormsDA Pam 310-3 Military Publications: Index of Doctrinal, Training, and Organizational

PublicationsDA Pam 310-4 Military Publications: Index of Technical Manuals, Technical Bulletins,

Supply Manuals (types 4, 6, 7, 8, and 9), Supply Bulletins, SupplyCatalogs (type CL), Lubrication Orders, and Modification WorkOrders

FM 21-5 Military Training ManagementFM 21-6 Techniques of Military InstructionFM 21-30 Military Symbols.LO 10-3930-255-20 Lubrication Order; Truck, Lift, Fork, Electric, Solid Rubber Tires,

2000-Pound Capacity, Army Model MHE-197, Baker Model FTD-020-EE, Federal Stock Number 3930-724-4058 (100-in. lift), FederalStock Number 3930-965-0075,(130 in. lift)

MIL-STD-162A Preparation for Delivery of Warehouse Materials Handling Equipmentfor Domestic and Overseas Shipment and Storage

SB 5-111 Supply of DA Approved Fire Extinguishers to Army Troop UsersTM 10-3930-255-10 Operator’s Manual; Truck, Lift. Fork, Electric, Solid Rubber Tires,

2000-Pound Capacity, Army Model MHE-197, Baker Model FTD-020-EE, Federal Stock Number 3930-724-4058 (100-in. lift), FederalStock Number 3930-965-0075 (130-in. lift)

TM 10-3930-255-20P Organizational Maintenance Repair Parts and Special Tools List; Truck,Lift, Fork, Electric, Solid Rubber Tires, 2000-Pound Capacity, ArmyModel MHE-197, Baker Model FTD-020-EE, Federal Stock Number3930-724-4058 (100-in. lift), Federal Stock Number 3930-965-0075(130-in. lift)

TM 10-1690A Industrial Motive Power Storage Batteries for Materials HandlingEquipment

TM 21-300 Driver Selection and Training (Wheeled Vehicles)TM 38-230 Preservation, Packaging, and Packing of Military Supplies and Equip-

mentTM 38-750 Army Equipment Record ProceduresTM 5-764 Electric Motor and Generator RepairTM 9-213 Painting Instructions for Field Use

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APPENDIX II

MAINTENANCE ALLOCATION

Section I. INTRODUCTION

1. General

This appendix contains the explanations of all themaintenance and repair functions authorized the variousmaintenance levels.

a. Section II (Maintenance Allocation Chart)designates overall responsibility for the performance ofmaintenance operations. The implementation ofmaintenance tasks upon the end item or component willbe consistent with the assigned maintenance operations.

b. Section III (Tool and Test EquipmentRequirements) contains a list of the special tools andspecial test equipment required for each maintenanceoperation as referenced from section II, Column K. Thissection cross-references a particular maintenanceoperation on the MAC when special tools and equipmentare required to perform a specific maintenance task.

c. Section IV (Remarks) contains supplementalinstructions, explanatory notes and/or illustrationsrequired for a particular maintenance operation. Thissection is cross-referenced to the MAC (sec. II, col. L).

2. Maintenance Operations

Maintenance is any action taken to keep material ina serviceable condition or to restore it to serviceabilitywhen it is unserviceable. Maintenance of materialincludes the following:

a. Service. Operations required periodically tokeep the item in proper operating condition, i.e., to clean,preserve, drain, paint, and replenish fuel, lubricants,hydraulic, and deicing fluids, or compressed air supplies.

b. Adjust. Regulate periodically to preventmalfunction. Adjustments will be made commensuratewith adjustment procedures and associated equipmentspecifications.

c. Aline. Adjust two or more components of anelectrical or mechanical system so that their

functions are properly synchronized or adjusted.

d. Calibrate. Determine, check, or rectify thegraduation of an instrument, weapon, or weaponssystem, or components of a weapons system.

e. Inspect. Verify serviceability and detect incipientelectrical or mechanical failure by close visualexamination.

f. Test. Verify serviceability and detect incipientelectrical or mechanical failure by measuring themechanical or electrical characteristics of the item andcomparing those characteristics with authorizedstandards. Tests will be made commensurate with testprocedures and with calibrated tools and/or testequipment referenced on the MAC.

g. Replace. Substitute serviceable components,assemblies, and subassemblies for unserviceablecounterparts or remove and install the same item whenrequired for the performance of other maintenanceoperations.

h. Repair. Restore to a serviceable condition byreplacing unserviceable parts or by any other actionrequired using available tools, equipment, and skills toinclude welding, grinding, riveting, straightening,adjusting, and facing.

i. Overhaul. Restore an end item to completelyserviceable condition as prescribed by serviceabilitystandards developed and published by nationalmaintenance points having maintenance responsibilityfor the item. This is accomplished through employmentof the technique of "Inspection and repair only asnecessary" (IROAN). Maximum use of diagnostic andtest equipment is combined with minimum disassemblyduring overhaul, "overhaul" may be assigned to any levelof maintenance except organizational, provided the time,tools, equipment, repair parts authorization,.

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54

and technical skills are available at that level. Normally,overhaul as applied to end items, is limited to depotmaintenance level.

j. Bebuild. Restore to a condition comparable tonew, by disassembling to determine the condition ofeach component part and reassembly using serviceable,rebuilt, or new assemblies, subassemblies, and parts.

3. Explanations of Columns (Sec. II)

a. Functional Group Number. The functional groupis a numerical group set up on a functional basis. Theapplicable functional grouping indexes (obtained from TB750-93-1) is listed on the MAC in the appropriatenumerical sequence. These indexes are normally set upin accordance with their function and proximity to eachother.

b. Component Assembly Nomenclature. Thiscolumn contains the functional grouping index heading,subgroup heading, and a brief description of the partstarting with the noun name.

c. Essentiality. The essentiality column reflectswhether or not an assembly, or repair part, is combatessential to the tactical use of the end item. The letter"E" in this column, indicates the items are combatessential.

d. Maintenance Operations and MaintenanceLevels. This column contains the various maintenanceoperations "A" through "J," service, adjust, etc. A symbolindicating the maintenance level placed in theappropriate column in line with an indicated maintenanceoperation authorizes that level to perform the function.The symbol indicates the lowest level of maintenanceresponsible for performing the function, but does notnecessarily indicate repair parts stockage at that level.Higher levels of maintenance are authorized to performthe indicated functions of lower levels. The symboldesignations for the various maintenance levels

are as follows:

O/C................................Operator or crewO ...................................OrganizationalDS .................................Direct SupportGS.................................General SupportD....................................Depot

e. Reference Note. This column is subdivided intwo columns. Column "K" references the tool and testequipment requirements (T & TE) (Sec. III). Column "L"references the remarks (Sec. IV).

4. Explanation of Columns (Sec. Ill)

a. Reference Code. This column consists of anumber and a letter separated by a dash. The numberreferences the T&TE requirements column on the MAC.The letter represents the specific maintenance operationthe item is to be used with. The letter is representativeof columns "A" through "J" on the MAC.

b. Maintenance Level. This column shows thelowest level of maintenance authorized to use the specialtool or test equipment.

c. Nomenclature. This column lists the name oridentification of the tool or test equipment.

d. Tool Number. This column lists themanufacturer’s code and part number, or Federal stocknumber, of tools and test equipment.

5. Explanation of Columns (Sec. IV)

a. Reference Code. This column consists of twoletters separated by a dash. The first letter referencescolumn "L." The second letter references a maintenanceoperation, column "A" through "J" on the MAC (sec. II).

b. Remarks. This column lists the remarks andother information pertinent to the operation beingperformed as indicated on the MAC (sec. II).

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Section II. MAINTENANCE ALLOCATION CHART

Maintenance Maintenance Noteoperations and levels ref

Functional Component assembly nomenclature A B C D E F G H I J K Lgroup No.

06 ELECTRICAL SYSTEM0607 Instrument panel

Hour meter ................................... ...... ...... ...... ...... ...... O/C ...... OPanel, instrument ......................... ...... ...... ...... ...... ...... ...... OSwitch, light.................................. ...... ...... ...... ...... ...... ...... O

0608 Miscellaneous itemsReceptacle battery ....................... ...... ...... ...... ...... ...... ...... ...... OSwitch, stoplight ........................... ...... ...... ...... ...... ...... O/C ...... O

0609 LightsLamps .......................................... ...... ...... ...... ...... ...... ...... ...... OLights ........................................... ...... ...... ...... ...... ...... ...... ...... O OResistors, lights ........................... ...... ...... ...... ...... ...... ...... O O

0611 HornButton, horn ................................. ...... ...... ...... ...... ...... ...... ...... O O ...... ...... ...... AHorn assembly ............................. ...... ...... ...... ...... ...... ...... O O

0612 BatteriesBattery, storage............................ ...... O/C ...... ...... ...... ...... O OCables, battery............................. ...... ...... ...... ...... ...... ...... ...... O

0613 Hull or chassis wiring harnessHarness, wiring ............................ ...... ...... ...... ...... ...... ...... ...... DS

10 FRONT AXLE1000 Front axle assembly

Axle assembly, driving ................. ...... O ...... ...... ...... ...... ...... DS DS GS1002 Differential

Differential assembly................... ...... ...... ...... ...... ...... ...... ...... GS GS11 REAR AXLE

1100 Rear axle assemblyAxle assembly, steering ............... ...... ...... O ...... ...... ...... ...... DS DS

1104 SteeringArm, steering................................ ...... O/C ...... ...... ...... ...... ...... DSAxle, steering ............................... ...... ...... ...... ...... ...... ...... ...... DS

12 BRAKES1201 Handbrakes

Brakeshoe assembly, motor ........ ...... ...... ...... ...... ...... ...... ...... DS DSCable, handbrake......................... ...... ...... ...... ...... ...... ...... ...... OControl linkage ............................. ...... ...... O ...... ...... ...... ...... ODrum, brake ................................. ...... ...... ...... ...... ...... ...... ...... DSLever, handbrake ......................... ...... ...... ...... ...... ...... ...... ...... O

1202 Service brakesBrake assembly ........................... ...... ...... O ...... ...... ...... ...... DS DSShoe assembly ............................ ...... ...... ...... ...... ...... ...... ...... DS

1204 Hydraulic brake systemMaster cylinder............................. ...... O ...... ...... ...... ...... ...... O DS ...... ...... ...... BTube assembly, metal .................. ...... ...... ...... ...... ...... ...... ...... OWheel, cylinder . .......................... ...... ...... ...... ...... ...... ...... ...... O DS ...... ...... ...... C

13 WHEELS1311 Wheel assembly

Bearing and seals, rear whee’s.... ...... O ...... ...... ...... ...... ...... OWheel assembly .......................... ...... ...... ...... ...... ...... ...... ...... O

1313 TiresTires, solid.................................... ...... ...... ...... ...... ...... ...... ...... DS

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14 STEERING1401 Steering assembly

Bearing, bellcrank ........................ ...... ...... ...... ...... ...... ...... ...... DSBellcrank ...................................... ...... ...... ...... ...... ...... ...... ...... DSDrag, link...................................... ...... ...... ...... ...... ...... ...... ...... DSRod assembly, tie ........................ ...... ...... ...... ...... ...... ...... ...... DSSteering gear assembly ............... ...... O O ...... ...... ...... ...... DS DSWheel, steering ............................ ...... ...... ...... ...... ...... ...... ...... O

18 BODY, CAB, HOOD AND HULL1801 Body, cab, hood, hull assemblies

Covers.......................................... ...... ...... ...... ...... ...... ...... ...... OGuards ......................................... ...... ...... ...... ...... ...... ...... ...... O

1805 FloorPlate, floor.................................... ...... ...... ...... ...... ...... ...... ...... O

1806 SeatsSeat assembly ............................. ...... ...... ...... ...... ...... ...... ...... O O

24 HYDRAULIC LIFT COMPONENTS2401 Hydraulic pump

Pump, rotary, power driven,hydraulic ................................... ...... ...... ...... ...... ...... ...... ...... O DS

2402 Hydraulic control valveValve, directional control .............. ...... ...... ...... ...... ...... ...... ...... DS DS

2403 Hydraulic control levers andlinkageBracket, control valve................... ...... ...... ...... ...... ...... ...... ...... OLevers, control ............................. ...... ...... ...... ...... ...... ...... ...... O

2404 Hydraulic tilt cylindersCylinder assembly, tilt .................. ...... ...... ...... ...... ...... ...... ...... O DS

2405 Hydraulic mast columnChain assembly ........................... ...... ...... O ...... ...... ...... ...... O OCrosshead.................................... ...... ...... ...... ...... ...... ...... ...... DS DSCylinder assembly, actuating,

hoist.......................................... ...... ...... ...... ...... ...... ...... ...... DS DSForks ............................................ ...... ...... ...... ...... ...... ...... ...... ORoller assembly ........................... ...... ...... ...... ...... ...... ...... ...... DSUpright assembly, inner ............... ...... ...... ...... ...... ...... ...... ...... DS

2406 Hydraulic lines and fittings ...............Cap, oil breather .......................... ...... O/C ...... ...... ...... ...... ...... OFilter element ............................... ...... ...... ...... ...... ...... ...... ...... OHoses assembly, rubber .............. ...... ...... ...... ...... ...... ...... ...... OTank, oil ....................................... ...... ...... ...... ...... ...... ...... ...... OValve, regulating .......................... ...... ...... ...... ...... ...... ...... ...... O O

40 ELECTRIC MOTORS4000 Motor assembly

Motor assembly, travel ................. ...... ...... ...... ...... ...... ...... DS DS DS GSMotor assembly, pump................. ...... ...... ...... ...... ...... ...... O O DS

4001 Rotor assembliesArmature, travel motor ................. ...... ...... ...... ...... ...... ...... ...... DSArmature, pump motor ................. ...... ...... ...... ...... ...... ...... ...... DS

Stator assembliesWinding, motor field ..................... ...... ...... ...... ...... ...... ...... ...... DS

4003 Brush holdersBrush, electrical contact............... ...... ...... ...... ...... ...... ...... ...... DS

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Holder, electrical contact, brush .. ...... ...... ...... ...... ...... ...... ...... DSEndbell ......................................... ...... ...... ...... ...... ...... ...... ...... DS

4005 Frame supports and housingsBearing, ball annular, drive

motors ...................................... ...... ...... ...... ...... ...... ...... ...... DS4007 Drive components

Adapter assembly, gear reduction ...... O/C ...... ...... ...... ...... ...... DS DS4010 Master control assembly

Contact, relay............................... ...... ...... ...... ...... ...... ...... ...... DSControl, interlock .......................... ...... ...... ...... ...... ...... ...... ...... DSSwitch, sensitive .......................... ...... ...... ...... ...... ...... ...... ...... DS

4011 Fuse and fuse holderFuse, cartridge ............................. ...... ...... ...... ...... ...... ...... ...... OFuse holder .................................. ...... ...... ...... ...... ...... ...... ...... DSLink, fuse ..................................... ...... ...... ...... ...... ...... ...... ...... DS

4012 SwitchesLever, switch ................................ ...... ...... ...... ...... ...... ...... ...... DSSwitch, accelerator....................... ...... ...... ...... ...... ...... ...... ...... DS DSSwitch, directional control ............ ...... ...... ...... ...... ...... ...... ...... DS

4014 ResistorResistor, adjustable ..................... ...... ...... DS ...... ...... ...... ...... DSResistor, fixed .............................. ...... ...... ...... ...... ...... ...... ...... DS

4015 RelayRelay, armature .......................... ...... ...... ...... ...... ...... ...... ...... DS

4017 RectifierDiode, rectifier .............................. ...... ...... ...... ...... ...... ...... ...... DS

4019 Radio interference suppressionStrap, static drag.......................... ...... ...... ...... ...... ...... ...... ...... DS

Section III. SPECIAL TOOL AND SPECIAL TEST EQUIPMENT REQUIREMENTS

Reference Maintenance Nomenclature Tool No.level

No special tools or equipment are re-quired by organizational, direct, gen-eral support, and depot personnelfor performing maintenance on thetruck, lift, fork.

Section IV. REMARKS

Reference Remarkscode

A - H Repair includes installing repair kit.B - H Repair includes installing repair kit.C - H Repair includes installing repair kit.

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INDEX

Paragraph PageAccelerator master assembly ............................................................................................................. . 68 42Battery ................................................................................................................................................ 28 23Battery box top and side covers ......................................................................................................... 47, 48 31-32Brake cable ........................................................................................................................................ 36 25Brake master cylinder......................................................................................................................... 39 27Brake rod............................................................................................................................................ 36 25Brakeshoes:

Adjustment ................................................................................................................................... 37 26Replacement................................................................................................................................ 38 27

Chain .................................................................................................................................................. 59 37Contact ............................................................................................................................................... 67 41Control relay ....................................................................................................................................... 67 41Control valve....................................................................................................................................... 54 34Crosshead rollers ............................................................................................................................... 58 36Data, tabulated ................................................................................................................................... 7 4Description, truck and components .................................................................................................... 6 2Directional control switch.................................................................................................................... 71 44Filter cartridge service ........................................................................................................................ 62 39Fork .................................................................................................................................................... 60 37Fuse replacement............................................................................................................................... 70 44Fusetron replacement ........................................................................................................................ 69 43Handbrake lever ................................................................................................................................. 35 24Harness, wiring................................................................................................................................... 29 23Headlight ............................................................................................................................................ 22 21Horn.................................................................................................................................................... 26 22Horn button......................................................................................................................................... 27 22Hoses, hydraulic ................................................................................................................................. 61 38Hourmeter .......................................................................................................................................... 18 20Hydraulic hose.................................................................................................................................... 61 38Hydraulic pump................................................................................................................................... 53 33Hydraulic pump motor ........................................................................................................................ 66 40Lamp replacement.............................................................................................................................. 24 21Lift and tilt control ............................................................................................................................... 54 34Lubrication, general ............................................................................................................................ 11 7Master cylinder (brake)....................................................................................................................... 39 27Preventive maintenance..................................................................................................................... 13, 14 11-13Pump motor ........................................................................................................................................ 66 40Pump switch ....................................................................................................................................... 56 35Relay .................................................................................................................................................. 68 42Return filter cartridge replacement ..................................................................................................... 62 39Seat assembly.................................................................................................................................... 51 33Specifications ..................................................................................................................................... 7 4Speed resistor .................................................................................................................................... 73 45Steer wheels....................................................................................................................................... 32 24Steering gear lash .............................................................................................................................. 44a 30Steering linkage.................................................................................................................................. 44b 31Steering wheel.................................................................................................................................... 45 31Stop and taillight ................................................................................................................................. 23 21Stoplight switch................................................................................................................................... 21 20Suction filter cartridge replacement.................................................................................................... 62 39

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Paragraph PageTabulated data.................................................................................................................................... 7 4Taillight resistor .................................................................................................................................. 25 22Thermal relay...................................................................................................................................... 74 46Tilt cylinder ......................................................................................................................................... 57 36Troubleshooting chart......................................................................................................................... 16 13Wheel replacement ............................................................................................................................ 41 29Wheel bearings (rear only) ................................................................................................................. 42 30Wheel brake ....................................................................................................................................... 37 26

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BY ORDER OF THE SECRETARY OF THE ARMY:

HAROLD K. JOHNSON,General, United States Army,

Official: Chief of Staff.

J. C. LAMBERT,Major General, United States Army,The Adjutant General.

Distribution:

Active Army:

USASA (1) Arsenals (2)DCSLOG (1) PG (2)CNGB (1) QM Fld Maint Shops (2)CAR (1) Units org Under fol TOE:USCONARC (2) (2 copies each)CofEngrs (6) 3-117CofSptS (1) 5-279Dir of Trans (1) 5-500 (BB)CC-E (1) 8-187USAMC (12) 9-197ARADCOM (2) 9-367ARADCOM Rgn (2) 10-37OS Maj Comd (3) 10-337LOGCOMD (1) 10-407USAMOCOM (2) 10-417USAWECOM (5) 10-445USAMICOM (5) 10-447USAMUCOM (5) 10-467USAECOM (5) 10-500 (EE,EA,ED,EG)USATECOM (5) 11-128USASMC (1) 12-512MDW (1) 29-51Armies (5) 29-53Instl (2) 29-56USMA (1) 29-57Svc Colleges (2) 29-105Br Svc Sch (2) except USAQMS (10) 29--107Army Dep (4) 31-105NLABS (4) 31-106USA Mob Equip Cen (46) 55-260USAQMTC (4) 55-457Mob Equip Manuals Fld Ofc (Ft Lee) (2) 55-458USA Tml Comd (2) 55-500 (BEJC)Army Tml (2) 57POE (2) 57-100

NG: State AG (3).

USAR: None.

For explanation of abbreviations used, see AR 320-50.

*U.S. GOVERNMENT PRINTING OFFICE: 1991 - 281-486/42930

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TM 10-3930-255-20 TRUCK, LIFT, FORK, ELECTRIC, 2000-LB CAPACITY ARMY MODEL MHE-197-1965

PIN: 028497-000

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